Light Truck Frame Joint Stiffness Study Phase 1 Final Report

More documents

Recommendations

Info

SENSITIVITY STUDY Crossmember Gage Inner Side Rail Gage Outer Side Rail Gage Weld Flange Width Upper Flange Width Cross Member Height Cross Member Width Rail Height Rail Width Figure 30: Main Effects Plot for Joint 5: Hat Section to Box Section Fore/Aft Bending Stiffness K θz Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 57
JOINT STIFFNESS TOOLBOX Introduction A design experiment was run using the Altair StudyWizard. These experiments included consideration of the linearity of the joint parameters and the interactions between them on the joint stiffness. The mathematical response of each joint was programmed into an Excel spreadsheet. Designers and engineers will be able to enter joint dimensions, thickness, and any discrete variables simulated in the DOE, and obtain calculated joint stiffnesses. The Excel spreadsheet allows the user to input any joint definition that is within the DOE experiment range. The spreadsheets also contain Design Rules and Observations to be considered when making design decisions. The Design Rules were created from finite element and sensitivity analysis data to help make stiffer joints. For example, in the case of Joints 1 and 3, where the crossmember is a round section, the design rules included two points: making the tube diameter as large as possible, and making the tube thickness as thick as large as possible. The Joint Observations contained information regarding joint deflection and welding information stemming from the analytical results. An example overview of the spreadsheet is shown in Figure 31. The spreadsheet for each of the joints is shown in Figures 32 through 41 with two figures for each joint; the first figure shows the input and calculated results for the joint stiffness, and the second figure shows the joint observations, notes and design rules. Joint #1: Tube Through Tube Stiffness Calculations Input (mm) Test Design Window Design Variables (mm) Case 1 Case 2 Joint Min (mm) Max (mm) Thickness Crossmember 2.5 2.5 2.5 2 6 Side Rail 2.8 2.8 2.8 2 6 Shape Animations Shape Variables (mm) animations\JCrossmember Diameter 57 57 57 50 100 animations\JSide Rail Height 125 125 125 75 150 animations\JSide Rail Width 125 125 125 75 150 Output Loading Animations Stiffness Calculations Case 1 Case 2 Test Joint Units animations\JKx Bending Stiffness (Mx) 3.235 3.235 3.477 kN-m/deg animations\JKy Torsion Stiffness (My) 3.271 3.271 12.715 kN-m/deg animations\JKz Fore/Aft Stiffness (Mz) 3.507 3.507 3.662 kN-m/deg Illustration Key: A = Side Rail B = Crossmember Design Rules: * Make the crossmember diameter as large as possible. * Make the crossmember as thick as possible. * Thickness and diameter of the crossmember should be increased together if possible. Joint Observations: * The crossmember is the most important part of this joint. The thickness of the crossmember is 3X more sensitive than the thickness of the side rail. * The maximum stress is in the crossmember at the connection to the inner side rail for all 3 Stiffness Cases. * The outer weld (the crossmember to outer side rail) could be a partial weld because this section of the joint has low stress. Notes: * Modify the input values (yellow) based on your design criteria. There are two columns in which in to input and evaluate data, case 1 and case 2. The calculated stiffness will be displayed in red. * Design variables are listed in order of influence on stiffness. * Click on the animation to the left of the variables and loading conditions to see an animation of respective shape variable or loading condition. * The mass calculation is based on 150 mm extension of joint members from the side rail to crossmember interface. (The crossmember is 150mm from the joint interface to the end of the crossmember). This caluclation is to serve as a reference, not the absolute value. * The password to unprotect cells in this spreadsheet is: steel. Mass 4.801 4.801 4.801 kg Yellow cells are user input data. Red cells are calculated numbers. Figure 31: Example of the Joint Stiffness Toolbox Spreadsheet Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 58
Page 1 and 2:
Light Truck Frame Joint Stiffness S
Page 3 and 4:
EXECUTIVE SUMMARY Background There
Page 5 and 6:
TABLE OF CONTENTS Introduction ....
Page 7 and 8: LITERATURE SEARCH Introduction A li
Page 9 and 10: LITERATURE SEARCH Joint Stiffness T
Page 11 and 12: FINITE ELEMENT ANALYSIS Introductio
Page 13 and 14: FINITE ELEMENT ANALYSIS Defining th
Page 15 and 16: FINITE ELEMENT ANALYSIS Load Applie
Page 17 and 18: FINITE ELEMENT ANALYSIS z L: Load F
Page 19 and 20: FINITE ELEMENT ANALYSIS Table 1: An
Page 21 and 22: TESTING PROCEDURE Test Repeatabilit
Page 23 and 24: TESTING PROCEDURE Joints 1 - 4 Pneu
Page 25 and 26: TESTING PROCEDURE Joint 1 - X Direc
Page 27 and 28: TESTING PROCEDURE Joint 1 - Torsion
Page 41 and 42: TESTING PROCEDURE Joint 5 - Hanging
Page 43 and 44: TESTING PROCEDURE Joint 5 - Z Direc
Page 45 and 46: TESTING PROCEDURE Joint Stiffness S
Page 47 and 48: TESTING PROCEDURE Table 2: Test Joi
Page 49 and 50: CORRELATION Table 3: Test and Analy
Page 51 and 52: SENSITIVITY STUDY The influence of
Page 53 and 54: SENSITIVITY STUDY C- Channel Gage C
Page 55 and 56: SENSITIVITY STUDY C- Channel Gage C
Page 57: SENSITIVITY STUDY Crossmember Gage
Page 61 and 62: JOINT STIFFNESS TOOLBOX Notes: * Mo
Page 71 and 72: APPENDIX A: ABSTRACTS Read Articles
Page 73 and 74: APPENDIX A: ABSTRACTS 7. SCF Design
Page 75 and 76: APPENDIX A: ABSTRACTS 15. Deformati
Page 77 and 78: APPENDIX A: ABSTRACTS reasonable ag
Page 79 and 80: APPENDIX A: ABSTRACTS frequency err
Page 81 and 82: APPENDIX A: ABSTRACTS 36. Dynamic R
Page 83 and 84: APPENDIX A: ABSTRACTS 43. Behavior
Page 85 and 86: APPENDIX A: ABSTRACTS 6. Connection
Page 87 and 88: APPENDIX B: MATERIAL TESTING REPORT
Page 109 and 110:
APPENDIX B: MATERIAL TESTING REPORT
Page 111 and 112:
APPENDIX C: TEST RESULTS Joint 1 Fo
Page 113 and 114:
APPENDIX C: TEST RESULTS Joint 2 Ve
Page 115 and 116:
APPENDIX C: TEST RESULTS Joint 3 To
Page 117 and 118:
APPENDIX C: TEST RESULTS Joint 5 Fo
Page 119 and 120:
APPENDIX D: DIAGRAM OF JOINT IN TES
Page 121 and 122:
Page 123:
show all

Light Truck Frame Joint Stiffness Study Phase 1 Final Report

Create successful ePaper yourself

Delete template?

Save as template?